l

PROCESS ECONOMICS

PROGRAM SRI INTERNATIONAL

Menlo Park, California

94025

Expires: July 1, 1981

PRICE SCHEDULE FOR REPORTS PHASES I THROUGH XI (PEP'75)

(Offered Only to Clients of PEP'79 and PEP'80)

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PROCESS ECONOMICS

PROGRAM SRI INTERNATIONAL

Menlo Pd. California

94025

Abstract

Process Economics Program Report No. 137

WASTE TREATMENT COSTS

(September 1980)

The past decade has seen the introduction of comprehensive

legislation by industrialized nations to control and reduce the

pollution of air, land, and water. Consequently, pollution abatement

costs to the chemical and related industries have risen sharply in real

terms since 1970. These costs are likely to continue to rise at least

until 1985.

The technology for pollution abatement Is generally the same as

that for mineral beneficiation and chemical production.

The application of SRI-developed modular capital and operating

costs to these operations provides a simple means to estimate waste

treatment costs for specific chemical plants.

PEP '78 GEH

Report No. 137

WASTE TREATMENT COSTS

by GEORGE E. HADDELAND

September 1980

A private report by the

PROCESS ECONOMICS PROGRAM

Menlo Park, California 94025

For detailed marketing data and information, the reader is

referred to one of the SRI programs specializing in marketing

research. The CHEMICAL ECONOMICS HANDBOOK Program covers

most major chemicals and chemical products produced in the

United States and the WORLD PETROCHEMICALS Program covers

major hydrocarbons and their derivatives on a worldwide basis.

In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services

provide detailed lists of chemical producers by company, prod-

uct, and plant for the United States and Western Europe.

ii

CONTENTS

1

2

3

4A

INTRODUCTION. ........................

SUMMARY ...........................

Pollution Abatement Legislation ............... Pollution Abatement Rxpenditures. .............. Capital Costs ....................... Operating Costs ......................

Waste Treatment Technology. ................. Modular Waste Treatment Costs ................ Fixed Capital Investment ................. Operating Costs ...................... Examples of Module Cost Estimates .............

POLLUTION ABATEMENT LEGISLATION AND EXPENDITURES. ......

Legislation in the United States. .............. Air Pollution ....................... Water Pollution ...................... Land Pollution (Solids Disposal). ............. Selected Reactions to U.S. Antipollution Legislation. ... Information Sources ....................

Legislation in Japan. .................... Air Pollution ....................... Water Pollution ...................... Land Pollution. ...................... Chemical Substances Control Law ..............

Rxpenditures in the United States .............. Capital Expenditures. ................... Operating Costs. .....................

Expenditures in Japan ....................

WASTEWATER TREATMENT TECHNOLOGY ...............

Pretreatment. ........................ Primary Treatment--Chemical ................. Objective ......................... IonExchange. ....................... Electrodialysis ...................... Reverse Osmosis ...................... Neutralization. ...................... Oxidation and Reduction .................. Chemical Addition ..................... Hydrolysis. ........................

Primary Treatment--Physical ................. Sedimentation ....................... Hydrocycloning. ......................

iii

1

3

13

13 13 16 22 24 25 26 28 30 32 32 33 33 38 41

43

45 46 46 54 56 58 58 60 63 65 67 67 67

CONTENTS

4A WASTEWATER TREATMENT TECHNOLOGY (continued)

Filtration and Centrifuging. ................ 70 Flotation. ......................... 72 Solvent Extraction ..................... 76 Crystallization. ...................... 77 Adsorption on Activated Carbon ............... 77

SecondaryTreatment ...................... 80 Air-Activated Sludge .................... 80 Oxygen-Activated Sludge. .................. 82 Facultative Lagoons. .................... 85 Trickle Filters Nitrification-Den;t;i;ila;i&: ..............................

85 87

Sand Filters ........................ 89 Tertiary Treatment ...................... 90 Foam Fractionation ..................... 90 Chlorination. ....................... 91 Ozonation. ......................... 92

Toxic Liquids Disposal .................... 95

4B GASEOUS WASTE TREATMENT AND DISPOSAL TECHNOLOGY. ....... 97

Pretreatment. ........................ 97 DrySystems .......................... 100 Gas-Solid Separation .................... 100 Adsorption on Activated Carbon ............... 101

Liquid Systems ........................ 105 Water and Solvent Scrubbing. ................ 105 Acid or Ammonia Neutralization ............... 105 Limestone Desulfurization. ................. 105

Waste Gas Disposal ...................... 106 Steam Generation and Incineration. ............. 106 Emergency Flaring. ..................... 107 Dispersion by a Stack. ................... 108

4c SOLID WASTE TREATMENT AND DISPOSAL TECHNOLOGY. ........ 111

Waste Solids Treatment .................... 111 Dewatering ......................... 111

.Drying ........................... 115 Incineration ........................ 116 Combustion. ........................ 119

Waste Solids Disposal. .................... 121 LandFarming ........................ 121 Stacking. .... i .'. .................. 122 Sanitary Landfill. ..................... 122 Hazardous-Waste Landfill .................. 124 Other Disposal Methods ................... 125

l

iv

CONTENTS

5 COST CALCULATIONS FOR WASTE TREATMENT MODULES. ........

Capital Cost Methods Used in This Study. ...........

Operating Costs. ....................... Module Cost Curves ......................

6 WASTE TREATMENT COSTS FOR SELECTED CHEMICAL INDUSTRIES ....

Methanol Plant Wastes, .................... Treatment Methods. ..................... Treatment Costs. ...................... Discussion of Costs. ....................

Ethylene Plant Wastes. .................... Treatment Methods. ..................... Treatment Costs. ...................... Discussion of Costs. ....................

Multiplant Wastes. ...................... Treatment Methods. ..................... Treatment Costs. ...................... Discussion of Costs. ....................

Phosphoric Acid Plant Wastes ................. Treatment Methods. ..................... Treatment Costs. ...................... Discussion of Costs. ....................

Conclusion ..........................

APPENDIX A Cost Basis. . . . . . . . . . . . . . . . . . . . . . . 211

APPENDIX B Calculations for the Equalization of a Waste Stream Flow Variable . . . . . . . . . . . . . . . . . . . . .

APPENDIX C Design Steps for a Completely Mixed Activated Sludge System . . . . . . . . . . . . . . . . . . . . .

APPENDIX D Fixed Bed Active Carbon Adsorber Capacity . . . . . . . 223

CITEDREFERENCES. . . e . . . . . . . . . . . . . . . . . . . . . . 225

V

127

130 133 134

189

190 190 190 193 195 195 195 199 200 200 200 204 205 205 207 207 208

213

217

3.1

3.2

3.3

a -

a

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

4.10

4.11

4.12

4.13

4.14

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

ILLUSTRATIONS

Annual Capital Expenditures by the U.S. Chemical Industry for Pollution Abatement. ...................

Annual Operating Costs of the U.S. Chemical Industry for Pollution Abatement. .....................

Annual Capital Expenditures by the Japanese Chemical Industry for Pollution Abatement as a Percentage of Total New Capital Investment .................

Wastewater Treatment Alternatives. ..............

Multiple-Chamber Alternate-Membrane Electrodialysis Cell ...

Settling Curves at Various Suspended Solids Concentrations . .

Batch Suspended Solids Flux Curve for Design .........

Approximate Solid Size Range for Solid-Liquid Separation Equipment .....................

Schematic Diagram of Dissolved-Air Flotation Tank with Recycle .........................

Activated Sludge System. ...................

Waste Gas Treatment Alternatives ...............

C&npressor Horsepower for Various Air Flow Rates .......

Pressure Drop for Air Flow Through Active Carbon at 70°F and 760 mm Hg. ....................

Waste Solid Treatment Alternatives ..............

Effect of Feed Size on Drying Centrifuge Capacity. ......

Effect of Feed Rate and Size on Drying Centrifuge Product Moisture .......................

Stacking Procedure for Waste Gypsum. .............

Guthrie Method for Modular Cost Estimates. ..........

Module Cost: Tanks .....................

Module Cost: Thickener, Clarifier ..............

Module Cost: Settling Lagoon ................

Module Cost: Oil Separator8 .................

Module Cost: Filters. ....................

Module Gost: Centrifuges- ..................

Module Cost: Hydraulic Cyclones ...............

Vii

34

39

42

44

57

68

69

71

75

81

98

99

104

112

113

114

123

129

136

137

138

139

140

141

142

5.9

5.10

5.11

5.12

5.13

5.14

5.15

5.16

5.17

5.18

5.19

5.20

5.21

5.22

5.23

5.24

5.25

5.26

5.27

5.28

5.29

5.30

5.31

5.32

5.33

5.34

5.35

5.36

ILLUSTRATIONS

Module Cost: Distillation System. .............

Module Cost: Evaporators. .................

Module Cost: Stripper, Steam or Flue Gas. .........

Module Cost: Lime Neutralizer ...............

Module Cost: System for Chemical Reaction or Precipitation .......................

Module Cost: Ion Exchange System. ... -. ........

Module Cost: Electrodialysfs and Reverse Osmosis Cells ...........................

Module Cost: Dissolved-Air Flotation Cell .........

Module Cost: Crystallization System ............

Module Cost: Active Carbon Adsorber for Liquid Stream ...

Module Cost: Solvent Extraction System. ..........

Module Cost: Biological Oxidation System Including Sludge Separation. .....................

Module Cost: Faculative Lagoon. ..............

Module Cost: Filters, Dual Media and Sand .........

Module Cost: Foam Fractionator. ..............

Module Cost: Ozonation System ...............

Module Cost: Denitrification System ............

Module Cost: Hydrolyzer ..................

Module Cost: Chlorinator for Ammonia Removal. .......

Module Cost: Chlorinator for Disinfection and Equipment for Water Quality Control. .................

Module Cost: Pumping System and Deep-Welling System ....

Module Cost: Liquid Incinerator ..............

Module Cost: Steam and Cooling Water Utilities. ......

Module Cost: Gas Combustor for Steam Generation ......

Module Cost: Gas Incinerator. ...............

Module Cost Flue Gas Desulfurization System. .......

Module Cost: Hydrocarbon Gas Flare. ............

Module Cost: Gas Dispersion Stack . . . . . . . . . . . . .

Viii

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

167

168

169

170

-

a

a

a ILLUSTRATIONS

5.37

a 5.38

5.39

5.40

5.41

a 5.42

5.43

5.44

5.45

5.46

5.47

5.48

5.49

5.50

a 5.51

5.52

5.53

6.1

6.2

6.3

6.4

B.l

c.1

c.2

c.3

D.l

D.2

Module Cost:

Module Cost:

Module Cost:

Module Cost:

Module Cost:

Module Cost:

Module Cost:

Module Cost:

Module Cost:

Module Cost:

Module Cost:

Module Cost:

Annnonia Neutralizer. ...........

Acid Gas Neutralizer ...........

Scrubbers, Hydrocarbon or Water. .....

Active Carbon Adsorber for Gaseous Stream.

Gas Compressor ..............

Dust Separator ..............

Gas Coolers ...............

Gas Refrigeration System .........

Rotary Direct Dryer. ...........

Dewatering Centrifuge. ..........

Solids Incinerator ............

Solids Cambustor .............

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

Disposal Cost: Land Farming ................

Disposal Cost: Gypsum Stacking. ..............

Disposal Cost: Sanitary Landfill. .............

Disposal Cost: Hazardous-Waste Landfill ..........

Transportation Cost ....................

Treatment of Methanol Plant Wastes .............

Treatment of Ethylene Plant Wastes (Ethane/Propane Pyrolysis) .................

Treatment of Multiplant Wastes ...............

Treatment of Process Phosphoric Acid Plant Wastes (Pihydrate Wet Process). ..................

Probability Plot of BOD Value. ...............

Determination of BOD Removal Rate Coefficient. .......

Determination of Oxygen Utilization Coefficient. ......

Determination of Sludge Production Coefficient .......

Breakthrough Curves for Three Columns in Series. ......

Service Time ss a Function of Bed Depth. ..........

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

191

196

201

206

214

218

220

221

224

224

iX

.

TABLES

. . 0

a

a

2.1 A Comparison of Modular Waste Treatment Estimates With Independently Estimated Values. ............. 11

3.1 U.S. National Ambient Air Quality Standards. ......... 15

3.2 Typical Effluent Limitations Promulgated by U.S. EPA According to the Federal Water Pollution Control Act Amendments of 1972. ..................... 17

3.3 U.S. EPA List of Priority Toxic Pollutants as of December 1978. ........................ 19

3.4 U.S. EPA-Proposed Water (Micrograms/Liter) Quality Criteria for Selected Toxic Pollutants ............ 21

3.5 Major Pollution Control Legislation by the U.S. Congress ... 27

3.6 U.S. Pollution Abatement Expenditures for Air, Water, and Solids, by Chemical Industry Segment ........... 36

3.7 U.S. Pollution Abatement Operating Costs for Air, Water, and Solids, by Chemical Industry Segment ........... 40

3.8 Japanese Pollution Abatement Expenditures, .......... 41

4.1 Typical Thickener and Clarifier Design Criteria. ....... 46

4.2 Water Pollutant Treatment Methods .............. 47

4.3 Toxic Inorganic and Organic Pollutants and Methods for Their Control. ...................... 48

4.4 Materials Rejected by Reverse Osmosis. ............ 59

4.5 Commercial Oxidizing and Reducing Agents and Their Possible Applications to Waste Treatment ........... 62

4.6 Typical Flocculants and Coagulants and Their Applications. .. 64

4.7 Some Typical Filter Applications ............... 73

4.8 Typical Centrifuge Performance Characteristics ........ 74

4.9 Activated Sludge Process Characteristics ........... 83

4.10 Typical Compounds Susceptible to Ozonation .......... 93

4.11 Applications of Gas-Solid Separation Equipment ........ 101

4.12 Vapors Adsorbed by Activated Carbon. ............. 103

4.13 U.S. EPA-Sponsored Waste Incineration Demonstration Plants ........................... .ll7

Xi

TABLES

.

5.1

5.2

5.3

6.1

6.2

6.3

6.4

B.l

SRI Module Investment Estimation Factors. ......... 131

Comparison of Chemical Equipment Module Costs Estimated by Different Methods, .............. 132

SRI Module Maintenance Cost Estimation Factors. ...... 134

Treatment Costs for Methanol Plant Wastes ......... 192

Treatment Costs for Ethylene Plant Wastes ......... 197

Treatment Costs for Combined Multiplant Wastes. ...... 202

Treatment Costs for Phosphoric Acid Plant Wastes (Dihydrate Wet Process) .................. 209

Cumulative Normal Probability Distribution. ........ 215

a

xii